Films including a water-soluble layer and a vapor-deposited organic coating

ABSTRACT

Films including a water-soluble layer and a vapor-deposited organic coating are disclosed. The films can optionally further include a vapor-deposited inorganic layer. The films exhibit enhanced barrier properties.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35 U.S.C. § 120 to U.S. patent application Ser. No. 16/015,252, filed on Jun. 22, 2018, U.S. Pat. No. 11,192,138, which claims the benefit, under 35 U.S.C. § 119(e), of U.S. Provisional Patent Application Ser. Nos. 62/523,298 and 62/523,290, both filed on Jun. 22, 2017, which are all herein incorporated by reference in their entirety.

TECHNICAL FIELD

The present disclosure generally relates to films including a water-soluble layer and a vapor-deposited organic coating.

BACKGROUND

Polymeric films including water-soluble components are useful in the construction of various articles and packaging. For example, such polymeric films can be used in health and hygiene products, including disposable diapers and training pants, incontinence articles, and feminine care products (e.g., pads and liners), in medical products such as bags for bodily fluids and/or waste (e.g., ostomy pouches), and in other household products such as trash bags, laundry bags, hamper liners, etc. Such polymeric films also can be used to form packaging for a variety of compounds. For example, the polymeric films can advantageously be formed into packaging for detergents, agrochemicals, water treatment chemicals, natural cleaning products containing bacteria/microbes, dyes, food, laundry, embroidery, beauty, personal care products, shaving products, health care products, and pharmaceuticals. The packaging can simplify dispersing, pouring, dissolving, and/or dosing of the contents contained within the packaging by eliminating the need to measure the contents, directly handle the contents, or dispense the contents. An example of a specific type of packaging advantageously formed from a water-soluble polymeric film is a soluble unit dose article. Soluble unit dose articles are useful to facilitate the delivery of predetermined quantities of one or more compositions, such as cleaning detergents, contained within the article. Soluble packaging can also be useful for solving some of the issues regarding trash entering waterways and oceans. For example, most packaging made from soluble films would not leave any litter in waterways or oceans, because the package would eventually dissolve and the remaining polymer would biodegrade. Known polymeric films including a water-soluble component suffer from a number of detriments however, including the migration of compounds and elements through the films. Also, water impinging on the package before intended contact such as from wet hands while handling can damage or weaken the package causing unintended leaking. Such detriments can limit the contents and usability of articles and packaging formed from the polymeric films.

SUMMARY

According to one embodiment, a film includes a layer of water-soluble polymeric material and a vapor-deposited coating joined to at least one surface of the layer of water-soluble polymeric material. The vapor-deposited coating includes a poly(p-xylylene) polymer.

According to another embodiment, a film includes a layer of water-soluble polyvinyl alcohol and a vapor-deposited coating joined to a primary surface of the layer of polyvinyl alcohol. The vapor-deposited coating includes poly(chloro-p-xylylene) polymer and the vapor-deposited coating has a thickness of about 25 nanometers to about 500 nanometers. The film has a thickness of about 76 microns and exhibits a water vapor transmission rate of about 62 g/(m²·day) [4 g/(100 in²·day)] to about 93 g/(m²·day) [6 g/(100 in²·day)] when measured in accordance to ASTM F-1249.

According to another embodiment, a film includes a layer of water-soluble polyvinyl alcohol and a vapor-deposited coating joined to a primary surface of the layer of polyvinyl alcohol. The vapor-deposited coating includes poly(chloro-p-xylylene) polymer and the vapor-deposited coating has a thickness of about 25 nanometers to about 500 nanometers. The film has a thickness of about 76 microns and exhibits an oxygen transmission rate of about 124 cc/(m²·day) [8 cc/(100 in²·day)] to about 279 cc/(m²·day) [18 cc/(100 in²·day)] when measured in accordance to ASTM D-3985 and F-1927.

According to another embodiment, a method of forming a film includes providing a layer of water-soluble polymeric material and vapor depositing an organic coating to at least one surface of the layer of water-soluble polymeric material. The organic coating includes a poly(p-xylylene) polymer.

According to another embodiment, a film includes a layer of water-soluble polymeric material, a vapor-deposited inorganic coating joined to at least one surface of the layer of water-soluble polymeric material, and a vapor-deposited organic coating joined to the vapor-deposited inorganic coating. The vapor-deposited inorganic coating includes a metal oxide. The vapor-deposited organic coating includes a poly(p-xylylene) polymer.

According to another embodiment, a film includes a layer of water-soluble polyvinyl alcohol, a vapor-deposited inorganic coating joined to at least one surface of the layer of water-soluble polyvinyl alcohol, and a vapor-deposited organic coating joined to a surface of the vapor-deposited inorganic coating. The vapor-deposited inorganic coating includes a metal oxide and has a thickness of about 2 nanometers to about 1000 nanometers. The vapor-deposited organic coating includes poly(chloro-p-xylylene) polymer and has a thickness of about 25 nanometers to about 500 nanometers. The film has a thickness of about 76 microns and exhibits a water vapor transmission rate of about 15.5 g/(m²·day) [1 g/(100 in²·day)] to about 93 g/(m²·day) [6 g/(100 in²·day)] when measured in accordance to ASTM F-1249.

According to another embodiment, a film includes a layer of water-soluble polyvinyl alcohol, a vapor-deposited inorganic coating joined to at least one surface of the layer of water-soluble polyvinyl alcohol, and a vapor-deposited organic coating joined to a surface of the vapor-deposited inorganic coating. The vapor-deposited inorganic coating includes a metal oxide and has a thickness of about 2 nanometers to about 1000 nanometers. The vapor-deposited organic coating includes poly(chloro-p-xylylene) polymer and has a thickness of about 25 nanometers to about 500 nanometers. The film has a thickness of about 76 microns and exhibits an oxygen transmission rate of about 77.5 cc/(m²·day) [5 cc/(100 in²·day)] to about 232.5 cc/(m²·day) [15 cc/(100 in²·day)] when measured in accordance to ASTM D-3985 and F-1927.

According to another embodiment, a method of forming a film includes providing a layer of water-soluble polymeric material, vapor depositing an inorganic coating to at least one surface of the layer of water-soluble polymeric material, and vapor depositing an organic coating to the surface of the inorganic coating. The inorganic coating includes a metal oxide. The organic coating includes a poly(p-xylylene) polymer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a cross-sectional view of a film according to one embodiment.

FIG. 2 depicts a cross-sectional view of a film according to another embodiment.

FIG. 3 . is a micrograph illustrating a vapor-deposited inorganic coating having a plurality of microfractures.

FIG. 4 is a micrograph illustrating a vapor-deposited inorganic coating having a plurality of microfractures, coated on top with an organic coating.

FIG. 5A illustrates a top view of a unit dose article having a flat top, a rounded bottom, and a compartment according to one example.

FIG. 5B illustrates a side view of the unit dose article of FIG. 5A.

FIG. 5C illustrates an end view of the unit dose article of FIG. 5A.

FIG. 5D illustrates a cross-sectional end view of the unit dose article of FIG. 5A.

FIG. 6A illustrates a top view of a unit dose article having a rounded top, a rounded bottom, and a compartment according to one example.

FIG. 6B illustrates a side view of the unit dose article of FIG. 6A.

FIG. 6C illustrates an end view of the unit dose article of FIG. 6A.

FIG. 6D illustrates a cross-sectional end view of the unit dose article of FIG. 6A.

FIG. 7A illustrates top view of an exemplary soluble unit dose article having a rounded top, a rounded bottom, and two overlapping compartments according to one embodiment.

FIG. 7B illustrates a side view of the unit dose article of FIG. 7A.

FIG. 7C illustrates an end view of the unit dose article of FIG. 7A.

FIG. 7D illustrates a cross-sectional end view of the unit dose article of FIG. 7A.

FIG. 8A illustrates an exemplary soluble unit dose article having a rounded top, a flat bottom, and two side-by-side compartments according to one embodiment.

FIG. 8B illustrates a side view of the unit dose article of FIG. 8A.

FIG. 8C illustrates an end view of the unit dose article of FIG. 8A.

FIG. 8D illustrates a cross-sectional end view of the unit dose article of FIG. 8A.

FIG. 9A illustrates soluble unit dose article having a rounded top, a rounded bottom, and two smaller side-by-side compartments each overlapping a larger bottom compartment according to one example.

FIG. 9B illustrates a side view of the unit dose article of FIG. 9A.

FIG. 9C illustrates an end view of the unit dose article of FIG. 9A.

FIG. 9D illustrates a cross-sectional end view of the unit dose article of FIG. 9A.

DETAILED DESCRIPTION Definitions

As used herein, when the term “about” modifies a particular value, the term refers to a range equal to the particular value, plus or minus twenty percent (+/−20%). For any of the embodiments disclosed herein, any disclosure of a particular value, can, in various alternate embodiments, also be understood as a disclosure of a range equal to about that particular value (i.e. +/−20%).

As used herein, when the term “approximately” modifies a particular value, the term refers to a range equal to the particular value, plus or minus fifteen percent (+/−15%). For any of the embodiments disclosed herein, any disclosure of a particular value, can, in various alternate embodiments, also be understood as a disclosure of a range equal to approximately that particular value (i.e. +/−15%).

As used herein, when the term “nearly” modifies a particular value, the term refers to a range equal to the particular value, plus or minus five percent (+/−5%). For any of the embodiments disclosed herein, any disclosure of a particular value, can, in various alternate embodiments, also be understood as a disclosure of a range equal to approximately that particular value (i.e. +/−5%).

As used herein, when the term “substantially” modifies a particular value, the term refers to a range equal to the particular value, plus or minus ten percent (+/−10%). For any of the embodiments disclosed herein, any disclosure of a particular value, can, in various alternate embodiments, also be understood as a disclosure of a range equal to approximately that particular value (i.e. +/−10%).

As used herein, the term “copolymer” means a polymer formed from two, or more, types of monomeric repeating units. The term “copolymer” as used herein further encompasses terpolymers, such as terpolymers having a distribution of vinyl alcohol monomer units, vinyl acetate monomer units, and butene diol monomer units. If the copolymer is substantially fully hydrolyzed, substantially no vinyl acetate monomeric units may be present.

Films Including a Water-Soluble Layer and a Vapor-Deposited Organic Coating

As will be described herein, films including a water-soluble layer and a vapor-deposited organic coating are disclosed. As an example, a cross-sectional view of an exemplary film is depicted in FIG. 1 . As illustrated in FIG. 1 , a film 100 can include a water-soluble layer 105 formed of a water-soluble polymeric material and a vapor-deposited organic coating 115 joined to one surface of the water-soluble layer 105.

As can be appreciated, the films described herein can have many variations. For example, a film can include a vapor-deposited organic coating on only one surface of the water-soluble layer as depicted in FIG. 1 or can have a vapor-deposited organic coating on both surfaces of the water-soluble layer in certain embodiments (not depicted).

In certain embodiments, a film can additionally include one, or more, intermediate layers between the water-soluble layer and the vapor-deposited organic coating. For example, the film 200, depicted in FIG. 2 , includes a water-soluble layer 205, a vapor-deposited inorganic coating 210 joined to one surface of the water-soluble layer 205, and a vapor-deposited organic coating 215 joined to the vapor-deposited inorganic coating 210. As can be appreciated, in other embodiments, both surfaces of the water-soluble layer can include a vapor-deposited inorganic coating and vapor-deposited organic coating or can include only one of a vapor-deposited inorganic coating and vapor-deposited organic coating. Additional intermediate layers, or additional coating layers, such as indicia layers, can further be included in certain embodiments. As can further be appreciated, the order of the layers can also vary. For example, a vapor-deposited organic coating can be joined to one surface of the water-soluble layer and a vapor-deposited inorganic coating can be joined to the vapor-deposited organic coating.

In certain embodiments, multiple coatings can be vapor-deposited. For example, in certain embodiments, a film can include a water-soluble layer and multiple vapor-deposited organic coating layers.

In certain embodiments, a film can include more than one water-soluble layer. For example, a film as described herein can include two water-soluble layers, three water-soluble layers, five water-soluble layers, or more water-soluble layers in various embodiments.

Vapor-Deposited Organic Coating

Application of a vapor-deposited organic coating can improve the properties and performance of a film in numerous ways. For example, films including a vapor-deposited organic coating can exhibit desirable chemical and physical properties including improved barrier properties, controlled dissolution times, and decreased tackiness. These improved properties can make such films useful for the formation of products typically formed from uncoated water-soluble films including water-soluble articles and water-soluble packaging materials. As can be appreciated however, the films described herein can also be useful for other articles and applications due to the excellent mechanical and chemical properties exhibited by the films. In certain embodiments, the vapor-deposited organic coatings described herein can be formed of a poly(p-xylylene) polymer.

As can be appreciated, poly(p-xylylene) polymers are generally water insoluble polymers. It has unexpectedly been found, however, that application of vapor-deposited poly(p-xylylene) polymers to a surface of a water-soluble layer can form advantageous films. For example, in certain embodiments, the films can retain certain water-solubility benefits while enhancing properties such as the film's barrier strength. In certain such embodiments, immersion of the film in water can cause the vapor-deposited organic coating to disintegrate into small and free flowing particles, or other remnants. Such remnants can be disposed, for example, in sewage streams without causing undesirable accumulation or other impermissible detriments. In certain embodiments, the remnants can be undetectable. In other embodiments, the films can be at least partially water insoluble but can exhibit beneficial properties such as desirable barrier properties In other embodiments, the film can film rupture to release the contents of a package, but the whole film does not dissolve completely as it will recovered from the water In certain embodiments, the films are not water-soluble.

Generally, poly(p-xylylene) polymers can be vapor-deposited and joined to a water-soluble layer through a suitable chemical vapor deposition process. For example, the poly(p-xylylene) polymers can be vapor-deposited using a thermal-based chemical vapor deposition process or a plasma-assisted chemical vapor deposition process in certain embodiments.

In certain embodiments, a thermal-based chemical vapor deposition can be used. For example, certain vapor-deposited organic coatings described herein can be formed from a chemical vapor deposition process which includes the steps of vaporizing a poly(p-xylylene) polymer precursor, pyrolyzing the poly(p-xylylene) polymer precursor to form a poly(p-xylylene) monomer, and cooling the poly(p-xylylene) monomer to cause condensation and polymerization of the monomer on at least one surface of a water-soluble layer.

As can be appreciated, plasma-assisted chemical vapor deposition processes can alternatively be used. Plasma-assisted chemical vapor deposition processes can be particularly advantageous because such processes can allow for formation of a poly(p-xylylene) polymer coating while minimizing melting, or other damage, to the water-soluble layer.

In certain embodiments, the poly(p-xylylene) polymer precursor can be dichloro-di(p-xylylene) which forms poly(chloro-p-xylylene) polymer. In certain such embodiments, dichloro-di(p-xylylene) can be vaporized at a temperature of 150° C. under an atmospheric pressure of 133.3 Pa (1 torr) in a chemical vapor deposition chamber and can subsequently be pyrolyzed at 690° C. and 66.7 Pa (0.5 torr) to form chloro-p-xylylene. Subsequent cooling of the chemical vapor deposition chamber can condense the chloro-p-xylylene to form a coating of poly(chloro-p-xylylene) on at least one surface of the water-soluble layer.

As can be appreciated, alternative poly(p-xylylene) polymer precursors can similarly be utilized to form a variety of alternative vapor-deposited organic coatings. For example, suitable poly(p-xylylene) polymer precursors can include different, or additional, halogen groups, or include reactive groups, such as amine groups, in various embodiments. In addition to poly(chloro-p-xylylene) polymer, non-limiting examples of suitable poly(p-xylylene) polymers which can form a vapor-deposited organic coating can include poly(para-xylylene) polymer, poly(dichloro-p-xylylene) polymer, α-perfluorodi-p-xylene polymer, and poly(tetrafluoro-p-xylylene) polymer.

Alternatively, or additionally, further materials, such as additional polymers, can also be vapor-deposited simultaneously with, subsequently with, or prior to, the poly(p-xylylene) polymer precursor. For example, in certain embodiments, one or more of tripropyleneglycol diacrylate (“TRPGDA”) and hexanediol diacrylate (“HDODA”) can be vapor-deposited with a poly(p-xylylene) polymer.

As can be further appreciated, additional chemical vapor deposition processes may also be suitable. For example, photochemical vapor deposition, initiated chemical vapor deposition, and aerosol assisted chemical vapor deposition may also be suitable processes to form a vapor-deposited organic coating in various embodiments.

As can be appreciated, poly(p-xylylene) polymers can also, or alternatively, be commercially sourced in certain embodiments. For example, suitable poly(p-xylylene) polymers marketed under the generic trade name “Parylene” can be used in certain embodiments. As can be appreciated, poly(chloro-p-xylylene) polymer is Parylene C. Additional varieties of Parylene which can be vapor-deposited on a layer of water-soluble polymer as described herein include Parylene N (e.g., poly(para-xylylene) polymer), Parylene D (e.g., poly(dichloro-p-xylylene polymer), Parylene AF-4 (e.g., α-perfluorodi-p-xylene polymer), Parylene A (including one reactive amine group per repeat unit), Parylene AM (including one methylene amine group per repeat unit), and Parylene VT-4 (e.g., poly(tetrafluoro-p-xylylene) polymer).

Generally, the thickness of the vapor-deposited organic coating can be selected by controlling the amount of polymeric precursors introduced in the chemical vapor deposition process. In certain embodiments, the thickness of a poly(p-xylylene) polymer coating can be about 1 μm/g of poly(p-xylylene) polymer precursor.

In any of the various embodiments described herein, the thickness of the vapor-deposited organic coating can be about 10 nanometers to about 1,000 nanometers, or any integer value from about 10 nanometers to about 1,000 nanometers, or any range formed by any of the preceding values, such as about 50 nanometers to about 500 nanometers, about 100 nanometers to about 300 nanometers, etc. As can be appreciated, the thickness of the vapor-deposited organic coating can influence the water-dispersibility of the films with thinner coatings have a greater propensity for breaking into dispersible sizes.

In certain embodiments, the vapor-deposited organic coating can be applied to less than substantially all of the water-soluble layer. For example, the vapor-deposited organic coating can be applied to about 50% to about 100% of the water-soluble layer, or any integer percentage from about 50% to about 100% of the water-soluble layer, or any range formed by any of the preceding values such as about 60% or more, or about 95% or more of the water-soluble layer. In certain embodiments, a mask can be used to apply the vapor-deposited organic coating to less than substantially all of the water-soluble layer. As can be appreciated, other methods of reducing the coating area can also be used. For example, the water-soluble layer can be selectively modified to reduce adhesion of a vapor-deposited organic coating to select areas. In certain embodiments, the vapor-deposited organic coating can be applied to substantially all of the water-soluble layer.

As can be appreciated, other organic polymers can also be vapor-deposited on a water-soluble layer to form films with advantageous properties. For example, in certain embodiments, the vapor-deposited organic coating can alternatively be formed of one or more of poly(carbonate urethane) urea (“PCUU”), poly(ester urethane) urea (“PEUU”), and poly(lactic-co-glycolic acid) (“PLGA”). In other embodiments, the vapor-deposited organic coating can be alternatively formed from one or more wax coatings such as paraffin, microcrystalline, petrolatum, vegetable-based, polyethylene based, and blends. Such organic polymers can also be applied to a water-soluble layer using chemical vapor deposition processes.

According to certain embodiments, a vapor-deposited organic coating can be joined to a layer of water-soluble layer either directly or indirectly. For example, in certain embodiments, an organic vapor-depositing coating can be applied directly to an unprocessed water-soluble layer using a chemical vapor deposition process as previously described. As used herein, an unprocessed water-soluble layer refers to a layer which has not undergone any treatment steps, such as ablation, after being cast from a water-soluble polymeric material.

Alternatively, in certain embodiments, a vapor-deposited organic coating can be applied to the water-soluble layer after the water-soluble layer has been prepared by, for example, cleaning. As can be appreciated, cleaning of the water-soluble layer can promote improved adhesion of the vapor-deposited organic coating and can minimize any defects in the organic coating.

Generally, a water-soluble layer can be cleaned in any suitable manner. For example, a water-soluble layer can be cleaned with a solvent treatment or a physical abrasion treatment in certain embodiments.

In certain embodiments, the water-soluble layer can be cleaned with an ablation process. In such embodiments, one or more surfaces of the water-soluble layer can be at least partially ablated to remove any undesirable material prior to application of the vapor-depositing organic coating. Additionally, certain ablation processes, such as plasma ablation processes, can also functionalize the surface and provide functional groups for the vapor-deposited organic coating to adhere to.

Generally, any suitable ablation process can be used including, for example, a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment. For example, a helium-oxygen plasma or an argon-oxygen plasma at a flow rate of 30.0 L/min at 100 W to about 150 W of power can be used to ablate the surface of a water-soluble layer prior to vapor deposition of an organic coating in certain embodiments. Other gases can also be used for plasma ablation including nitrogen and ammonia. As can be appreciated, the surface of a water-soluble layer can be partially ablated, substantially fully ablated, or fully ablated in various embodiments.

Alternatively, in certain embodiments, the vapor-deposited organic coating can be applied over an intermediate layer. For example, a vapor-deposited organic coating can be applied to an indicia layer, or to a vapor-deposited inorganic coating in various embodiments.

Intermediate Inorganic Coating

In certain embodiments, the films described herein can include a vapor-deposited inorganic coating as depicted in, for example, FIG. 2 . Inclusion of a vapor-deposited inorganic coating can provide various improvements to a film. For example, a film including a vapor-deposited inorganic coating can further exhibit improved barrier properties and can obviate any need to clean the water-soluble layer prior to application of the vapor-deposited organic coating.

In certain embodiments, suitable vapor-deposited inorganic coatings can be formed of metal oxides. As used herein, metal oxides include aluminum oxides, magnesium oxides, titanium oxides, zinc oxides, as well as metalloid oxides such as silicon oxides. As can be appreciated, metal oxides can be vapor-deposited using a variety of processes. For example, a metal oxide layer can be vapor-deposited using a chemical vapor deposition process in certain embodiments. Generally, most chemical vapor deposition processes are suitable due to the stability of the metal oxides and metal oxide precursors. Within these chemistries various stochiometries are possible and when we refer to an oxide we refer to any of the possible stochiometries.

In certain embodiments, a plasma enhanced chemical vapor deposition can be used to form the vapor-deposited inorganic coating. Suitable precursor compounds which can be vaporized to form the inorganic layer can include, for example, tetramethylsilane (“TMS”) and trimethylaluminum (“TMA”). TMS and TMA can respectively form silicon dioxide (“SiO₂”) and aluminum oxide (“Al₂O₃”) coatings. For example, a suitable TMS can be hexamethyldisiloxane (“HMDSO”) in certain embodiments. Power and flow rates can be determined based on variables such as the size of the substrate to be coated and the desired thickness of the vapor-deposited organic coating.

In certain embodiments, an atomic layer chemical vapor deposition process can alternatively be used. Atomic layer deposition is a chemical vapor deposition process based on sequential, self-saturating surface reactions. In such processes, precursors are pulsed into a chemical vapor deposition chamber and allowed to build up layer by layer.

Alternatively, physical vapor deposition processes can be used in certain embodiments. Physical vapor deposition processes differ from chemical vapor deposition processes by instead using physical processes such as heating or sputtering to produce vapor from a solid precursor. The vapor adsorbs onto the substrate to form a thin layer. In certain embodiments, suitable physical vapor deposition processes to form an inorganic layer can include sputtering, such as magnetron sputtering, thermal evaporation, and e-beam evaporation.

It has been discovered that vapor-deposited inorganic coatings can exhibit a plurality of microfractures which develop under various circumstances such as the processing conditions used to handle the film and the thickness of the inorganic coating. In certain embodiments, the vapor-deposited organic coating can overlay, and seal, the microfractures in the inorganic coating. For example, a vapor-deposited organic coating can cover a portion, substantially all, or all, of the microfractures present in the vapor-deposited inorganic coating. As can be appreciated, the vapor-deposited organic coating can be substantially, or entirely, free of microfractures.

In any of the various embodiments described herein, the thickness of the vapor-deposited inorganic coating can be about 2 nanometers to about 1,000 nanometers, or any integer value from about 2 nanometers to about 1,000 nanometers, or any range formed by any of the preceding values, such as about 100 nanometers to about 500 nanometers, about 100 nanometers to about 300 nanometers, etc.

In certain embodiments, the vapor-deposited inorganic coating can be applied to less than substantially all of the water-soluble layer. For example, the vapor-deposited inorganic coating can be applied to about 50% to about 100% of the water-soluble layer, or any integer percentage from about 50% to about 100% of the water-soluble layer, or any range formed by any of the preceding values such as about 60% or more, or about 95% of the water-soluble layer. In certain embodiments, a mask can be used to apply the vapor-deposited inorganic coating to less than substantially all of the water-soluble layer. As can be appreciated, other methods of reducing the coating area can also be used. For example, the water-soluble layer can be selectively modified to reduce adhesion of a vapor-deposited inorganic coating to select areas. In certain embodiments, the vapor-deposited inorganic coating can be applied to substantially all of the water-soluble layer.

FIG. 3 is a micrograph illustrating a vapor deposited inorganic coating having a plurality of microfractures. FIG. 4 is a micrograph illustrating a vapor-deposited film where a Parylene organic coating was deposited on top of an inorganic coating, with the underlying inorganic coating having a plurality of microfractures.

Water-Soluble Layers

As can be appreciated, the water-soluble layer of the film can be formed of any of a variety of water-soluble polymeric materials. As used herein, water-soluble polymeric materials are materials that, when formed as part of a film, dissolve in about 90 seconds or less when immersed in water having a temperature of about 20° C. Advantageously, suitable water-soluble layers of a film can dissolve at temperatures of about 24° C. or less, or about 10° C. or less in certain embodiments.

Examples of suitable water-soluble polymeric materials to form layers of the film can include polyvinyl alcohols (“PVOH”), polyvinyl alcohol copolymers, polyvinyl pyrrolidone, polyalkylene oxides such as polyethylene oxide, copolymers of butene diol and vinyl acetate (“BVOH”), acrylamide, acrylic acid, cellulose, cellulose ethers, cellulose esters, cellulose amides, polyvinyl acetates, polycarboxylic acids and salts, polyethylene glycol, polyaminoacids or peptides, polyamides, polyacrylamide, copolymers of maleic/acrylic acids, polysaccharides including starch and gelatin, natural gums such as xanthum and carragum, polyacrylates and water-soluble acrylate copolymers, methylcellulose, carboxymethylcellulose sodium, dextrin, ethylcellulose, hydroxyethyl cellulose, hydroxypropyl methylcellulose, maltodextrin, polymethacrylates, homopolymers thereof, copolymers thereof, and combinations thereof. In certain embodiments, the water-soluble polymeric material can be one or more of a polyvinyl alcohol, a polyvinyl alcohol copolymer, and hydroxypropyl methyl cellulose (“HPMC”). In certain embodiments, the water-soluble polymeric material can be free of carboxylate groups. As can be appreciated however, the present disclosure is not particularly limited and can be used with any other known water-soluble polymeric materials.

The water-soluble polymeric material can have any suitable weight average molecular weight. For example, in certain embodiments, the water-soluble polymeric material can have a weight average molecular weight of about 1,000 to about 1,000,000, or any integer value from about 1,000 to about 1,000,000, or any range formed by any of the preceding values such as about 10,000 to about 300,000, about 20,000 to about 150,000, etc.

In certain embodiments, mixtures of water-soluble polymeric materials can also be used. Mixtures of one or more water-soluble polymeric materials can be useful to control the mechanical and/or dissolution properties of articles formed from the water-soluble polymeric materials. In such embodiments, the water-soluble polymeric materials can be selected on considerations such as the degree of water solubility, mechanical strength, and chemical miscibility of the materials.

In certain embodiments, suitable mixtures of water-soluble polymeric materials can have different weight average molecular weights. For example, a suitable mixture can include a first PVOH polymer, or copolymer thereof, having a weight average molecular weight of about 10,000 to about 40,000 (e.g., about 20,000) and a second PVOH, or copolymer thereof, having a weight average molecular weight of about 100,000 to about 300,000 (e.g., about 150,000). As can be appreciated however, it can also be advantageous in certain embodiments to select water-soluble polymeric materials which have similar molecular weights.

In certain embodiments, suitable water-soluble polymeric materials can be formed of a blend of different polymers or co-polymers. For example, suitable blends can include a polylactic acid polymer and a polyvinyl alcohol polymer. In certain embodiments, about 1% to about 35%, by weight, of the blend can be polylactic acid polymer and about 65% to 99%, by weight, of the blend can be polyvinyl alcohol.

Suitable water-soluble polymeric materials can have any suitable degree of hydrolysis. For example, suitable PVOH polymeric materials can have a degree of hydrolysis of about 60% to about 100% (e.g., about 99.95%), or any integer percentage from about 60% to about 100%, or any range formed by any of the preceding values such as about 60% to about 95%, about 80% to about 90%, etc. As can be appreciated, the degree of hydrolysis can vary depending upon the polymer, desired water solubility, and the molecular weight. For example, a BVOH copolymer can be substantially fully hydrolyzed in certain embodiments while retaining water solubility.

In certain embodiments, the water-soluble layers of films can include relatively small amounts of moisture. The moisture can prevent cracking of the water-soluble layers of a film. Generally, suitable levels of the moisture can include about 2% water to about 15% water by weight of the water-soluble layers. In certain embodiments, suitable levels of the moisture can alternatively include about 3.5% water to about 10% water by weight of the water-soluble layers. As can be further appreciated, the moisture levels can vary depending on environmental conditions and can reach ranges outside of about 2% water to about 15% water. For example, in very dry conditions, the water-soluble layers can reach a moisture level of about 1% water or less. In very humid environments, the water-soluble layers can reach a moisture level of greater than about 15% water.

Certain films described herein can include only a single water-soluble layer formed from any of the water-soluble polymeric materials described herein. In such embodiments, the water-soluble layer can generally be formed at any suitable thickness which demonstrates suitable properties such as barrier strength and solubility. For example, the water-soluble layer can have a thickness of about 5 micrometers to about 300 micrometers, any integer value from about 5 micrometers to about 300 micrometers, or any range formed by any of the preceding values such as 35 micrometers to about 150 micrometers, and about 50 micrometers to about 100 micrometers.

Alternatively, a film as described herein can include additional water-soluble layers with the vapor-deposited organic, or inorganic, coatings applied to the surfaces of the outermost layer(s). Generally, multi-layer films can be formed in any suitable way. For example, multi-layer films can be co-extruded as known in the art. Alternatively, multi-layer films can be formed through a lamination or solvent welding process. As can be appreciated, many variations are possible. For example, each layer can be formed from the same polymeric material. The use of a single polymeric material can be useful to minimize compatibility issues between polymers having different characteristics such as different molecular weights. Alternatively, at least one of the layers can be formed of a second polymeric material. As can be appreciated, the second polymeric material can generally be any polymer or co-polymer which can satisfactorily form a film with the polymeric material of the other layers. The second polymeric material can be a water-soluble material such as another PVOH polymer or can be a water-insoluble polymeric material such as polyethylene or ethylene vinyl acetate in certain embodiments. The use of a second water-soluble polymeric material can allow for water-soluble layers, and films, having specific properties to be formed more easily than by blending multiple polymers together within a single water-soluble layer.

In any of the embodiments describing multiple water-soluble layers, the number of layers can vary. For example, the films can include 3 water-soluble layers, 5 water-soluble layers, 7 water-soluble layers, 9 water-soluble layers, or more than 9 water-soluble layers in various embodiments.

The overall thickness of a film including multiple water-soluble layers can generally vary depending on the desired dissolution time and barrier properties. In certain embodiments, the overall thickness of such films can be about 5 micrometers to about 300 micrometers. In certain embodiments, a film having multiple water-soluble layers can have a thickness of about 25 micrometers to about 200 micrometers. In certain embodiments, a film having multiple water-soluble layers can have a thickness of about 50 micrometers to about 100 micrometers.

Additional Components Included in the Water-Soluble Layers

As can be appreciated, any of the water-soluble layers described herein can further include a large number of optional components. For example, water-soluble layers can additionally include one or more plasticizers and gas-barrier additives. When included, such components can be blended with the water-soluble polymeric material before formation of the water-soluble layer.

For example, any of the water-soluble polymeric materials described herein can further include one or more plasticizers to improve the rheological properties of the water-soluble layer. In such embodiments, a plasticizer can improve the flexibility and plasticity of the final film. As can be appreciated, when a plasticizer is included in a water-soluble layer as described herein, the size and mobility of the plasticizer can influence the barrier properties of the film. For example, less mobile plasticizers such as sorbitol can facilitate the formation of water-soluble layers with greater barrier properties than water-soluble layers including a more mobile plasticizer such as glycerin. Suitable plasticizers can include, but are not limited to, glycerin, ethylene glycol, diethylene glycol, hexylene glycol, triethylene glycol, propylene glycol, polyethylene glycol, polypropyl glycol, alkyl citrate, sorbitol, isosorbide, pentaerythritol, glucamine, N-methylglucamine, sodiumcumenesulfonate, water, and mixtures thereof. In certain examples, the plasticizer can be glycerin. As can be appreciated, other plasticizers can also be suitable including vegetable oil, polysorbitols, polyethylene oxide, dimethicone, mineral oil, paraffin, C₁-C₃ alcohols, dimethyl sulfoxide, N, N-dimethylacetamide, sucrose, corn syrup, fructose, dioctyl sodium-sulfosuccinate, triethyl citrate, tributyl citrate, 1,2-propylenglycol, mono, di- or triacetates of glycerin, natural gums, citrates, and mixtures thereof.

In any of the various embodiments including a plasticizer, the plasticizer can be included, by weight of the water-soluble layer, at a level of from about 8% to about 30%, or any integer percentage from about 8% to about 30%, or any range formed by any of the preceding values, such as about 8% to about 25%, about 8% to about 20%, about 10% to about 15%, etc. As can be appreciated, a mixture of multiple plasticizers can also be included in any embodiment including a plasticizer to, for example, tailor the rheological and barrier properties of the water-soluble layer.

In certain embodiments, the plasticizer can be glycerin and can be included at about 1% to about 15% by weight of the water-soluble layer. In other embodiments, the plasticizer can be polyethylene glycol. In certain such embodiments, polyethylene glycol can be included at about 1% to about 7.5%, by weight of the water-soluble layer.

The amount of plasticizer can be verified using techniques known in the art. For example, the amount of glycerin can be determined through use of a gas chromatography with a flame ionization detector (“GC-FID”). In such methods, ethanol can be used to extract glycerin from a small portion of the water-soluble layer or resin. The quantity of glycerin can be determined by comparing to a known commercial glycerin material. As can be appreciated, other processes can be used to determine the quantity of other types of plasticizers including, for example, time of flight mass spectroscopy (“MALDI-TOF MS”), and Raman spectroscopy.

Certain water-soluble layers as described herein can optionally include a gas-barrier additive to further improve the barrier properties of the film. Generally, suitable gas-barrier additives can include any compound, or polymers, compatible with the water-soluble polymeric material which improves the film's barrier properties. For example, suitable gas-barrier additives can include nanoclays, cellulose nano-fibrils, cellulose nano-crystals, talc, graphene, and polymers such as chitin, cellulose, starch, soy, whey, and gluten. An example of a suitable nanoclay is methyl-bis(hydroxyethyl)octadecyl ammonium surface compatibilized montmorillonite clay.

In any of the embodiments including a gas-barrier additive, the gas-barrier additive can be added in any suitable manner. For example, the gas-barrier additive can be blended into the water-soluble polymeric material feed stock and then thoroughly dispersed to exfoliate the additive. When included, a gas-barrier additive can be added at any suitable quantity that does not cause determents to the film. For example, a gas-barrier additive can be included, by weight of the water-soluble layer, at about 0.1% to about 5% in certain embodiments, at about 0.5% to about 4% in certain embodiments, at about 1% to about 3% in certain embodiments, and at about 2% in certain embodiments.

As can be appreciated, the water-soluble layers can still optionally include auxiliary agents and processing agents such as plasticizer compatibilizers, lubricants, release agents, surfactants, fillers, extenders, cross-linking agents, antiblocking agents, antioxidants, detackifying agents, antifoams, foaming agents, bleaching agents (e.g., sodium metabisulfite or sodium bisulfite), aversive agents such as bitterants (e.g., denatonium benzoate, denatonium saccharide, denatonium chloride, sucrose octaacetate, quinine, flavonoids such as quercetin and naringen, and quassinoids such as quassin and brucine) and pungent agents (e.g., capsaicin, piperine, allyl isothiocyanate, and resinferatoxin) as known in the art. Suitable examples of fillers, extenders, antiblocking agents, wetting agents, and/or detackifying agents can include starches, modified starches, crosslinked polyvinylpyrrolidone, crosslinked cellulose, microcrystalline cellulose, silica, metallic oxides, calcium carbonate, talc and mica.

Suitable lubricants and release agents can include fatty acids and their salts, fatty alcohols, fatty esters, fatty amines, fatty amine acetates, fatty amides, and silicones.

Suitable surfactants for the water-soluble layers for a film described herein can include nonionic, cationic, anionic and zwitterionic surfactants. Specific examples of suitable surfactants can include, but are not limited to, polyoxyethylenatedpolyoxypropylene glycols, alcohol ethoxylates, alkylphenol ethoxylates, tertiary acetylenic glycols and alkanolamides (nonionics), polyoxyethylenated amines, quaternary ammonium salts and quaternized polyoxyethylenated amines (cationics), and amine oxides, N-alkylbetaines and sulfobetaines (zwitterionics). Other suitable surfactants can include dioctyl sodium sulfosuccinate, lactylated fatty acid esters of glycerol and propylene glycol, lactylic esters of fatty acids, sodium alkyl sulfates, polysorbate 20, polysorbate 60, polysorbate 65, polysorbate 80, lecithin, acetylated fatty acid esters of glycerol and propylene glycol, and acetylated esters of fatty acids, and combinations thereof.

In embodiments of a water-soluble layer including an aversive agent such as denatonium benzoate, the aversive agent can be included in suitable quantities to ensure that the aversive effect provides an adequate response without interfering with the properties of the film. For example, denatonium benzoate can be included at about 100 parts-per-million (“ppm”) to about 500 ppm.

As can be appreciated, any of the various water-soluble layers for a film described herein can be tailored by including a selection of such optional components. In embodiments wherein the water-soluble layer includes multiple layers, any of the optional components can be included only in certain layers or can be included in each of the layers. For example, in certain embodiments, an aversive agent can be included only in layers likely to be contacted by humans. It can also be useful to include a gas-barrier additive only in inner water-soluble layers. Including the gas-barrier additive in the inner water-soluble layers can minimize any detriments caused by the gas-barrier additive such as the sealing properties of the film. As can be appreciated, certain gas barrier additives may have no effect on sealing properties and can be included in any layer.

Methods of Making a Water-Soluble Layer

Any of the water-soluble layers described herein can be formed through any suitable process including extrusion, solution casting, admixing, co-casting, and welding of the water-soluble polymeric material together with any of the optional components, such as plasticizer. As can be appreciated however, it can be advantageous in certain embodiments to form water-soluble layers using a cast extrusion process or blown extrusion processes.

Extrusion process can provide a number of advantages over alternative processes such as solution casting. For example, extrusion processes can facilitate the inclusion of additional components such as additional resins and gas-barrier additives, and can facilitate the formation of multi-layer films. Extrusion processes can also be used to extrude compositions that phase separate. Further, extrusion processes can offer improvements to both the ease of manufacturing and the cost compared to other processing methods. For example, certain water-soluble polymeric materials can exhibit a relatively large temperature difference between the melting temperature and the decomposition temperature. This difference can facilitate the use of extrusion processes by minimizing product loss to thermal decomposition. Generally, the water-soluble layers for films described herein can be formed using known extrusion processes including cast extrusion processes and blown extrusion processes.

The films described herein can be further modified through unilateral or bilateral film orientation. Generally, any of the films can be orientated through known techniques such as the use of elevated temperature biaxial orientation using a dedicated machine. Bilaterally orientated films can exhibit a variety of improved properties including improved barrier properties.

Film Properties

The films described herein can exhibit a number of beneficial properties including excellent barrier properties.

Barrier Properties

The films described herein exhibit improved barrier properties as demonstrated by favorable oxygen transmission rates and water vapor transmission rates. For example, any of the films described herein, including any alternative embodiments, can have oxygen transmission rates measured in accordance to ASTM D-3985 and F-1927 of about 62 cc/(m²·day) [4 cc/(100 in²·day)] to about 310 cc/(m²·day) [20 cc/(100 in²·day)] or any integer value from about 62 cc (m²·day) [4 cc/(100 in²·day)] to about 310 cc/(m²·day) [20 cc/(100 in²·day)], or any range formed by any of the preceding values such as about 77.5 cc/(m²·day) [5 cc/(100 in²·day)] to about 279 cc/(m²·day) [18 cc/(100 in²·day)], and about 124 cc/(m²·day) [8 cc/(100 in²·day)] to about 232.5 cc/(m²·day) [15 cc/(100 in²·day)], etc.

Any of the films described herein, including any described in alternative embodiments, can have a water vapor transmission rate measured in accordance to ASTM F-1249 of about 7.75 g/(m²·day) [0.5 g/(100 in²·day)] to about 248 g/(m²·day) [16 g/(100 in²·day)], or any integer value from about 7.75 g/(m²·day) [0.5 g/(100 in²·day)] to about 248 g/(m²·day) [16 g/(100 in²·day)], or any range formed by any of the preceding values such as, about 46.5 g/(m²·day) [3 g/(100 in²·day)] to about 124 g/(m²·day) [8 g/(100 in²·day)], and 62 g/(m²·day) [4 g/(100 in²·day)] to about 93 g/(m²·day) [6 g/(100 in²·day)], etc. As can be appreciated, such oxygen and water vapor transmission rates can be substantially lower than known PVOH films.

As used herein, oxygen transmission rates measured according to ASTM D-3985 and F-1927 as described in the test method section.

As used herein, water vapor transmission rates measured according to ASTM F-1249 were measured as described in the test method section.

As can be further appreciated, the films described herein can also demonstrate reduced transmission and migration rates for other compounds such as compounds contained within a package formed of the described films or compounds contained with the film. For example, the films can exhibit improved resistance to the migration of optical dyes, surfactants, and perfumes contained within a unit dose article. Additionally, compounds such as bittering agents contained within the film can be resistant to migration out of the film.

As can be appreciated, improving the barrier properties of a film can cause articles formed from the films to exhibit a number of beneficial improvements. For example, reduced oxygen migration can improve the stability of compositions contained with the articles.

Other benefits are also possible. For example, improved barrier properties can prevent migration of chemicals into, or out of, packages formed from the films described herein. Such properties can improve the lifespan of the packaging or prevent “weeping” or tacky feel as chemicals migrate out of the packaging. As can be appreciated, the vapor-deposited organic coating is water insoluble and can further enhance such properties.

Articles

In certain embodiments, some, or all, of the films described herein can be used to form unit dose articles, such as soluble unit dose articles. Soluble unit dose articles are packages containing a pre-measured quantity of one or more compositions, such as detergents. The compositions can be included in a compartment formed by sealing one or more films together. As can be appreciated, soluble unit dose articles provide convenient dispensing of compositions for applications such as laundry and dishwashing.

As can be appreciated, other articles can alternatively be formed from the films described herein. For example, packaging for water-softening compositions, medical compositions, health care compositions, nutraceuticals compositions, shaving compositions, personal cleansing compositions, hard surface cleaning cleansing compositions, bacteria/microbes for natural cleaning, pharmaceutical compositions, dental care compositions, beauty care compositions, disinfectant compositions, antibacterial compositions, antiseptic compositions, food, herbs, flavours, and aids or supplements thereof can be formed in various embodiments. Additional details of various possible articles are disclosed in U.S. Patent App. 2002/0150708 and U.S. Patent App. 2009/0250370. Additionally, the films can be useful for the formation of soluble laundry bags including those described in U.S. Patent App. No. 2002/0150708.

In certain embodiments, a vapor-deposited organic coating can be useful to make water-dissolvable articles that only dissolve when water is applied to a selected surface of the article. For example, personal care compositions or laundry can be packaged in articles formed from films which are dissolvable only when water is applied to a particular surface such as an inner surface. Other dry or low water content articles can be packaged such as durable or semi-durable items such as razors, toothbrushes, in addition to single use articles such as tampons, diapers and other sanitary protection items. In some examples, the package could be used as a tertiary package. As can be appreciated, the exterior surfaces of such articles can be handled without concern for water or moisture due to the water insolubility of the vapor-deposited organic coating. Use of the article by, for example, dispensing the personal care composition or loading of the laundry bag into a washing machine, can expose the inner surface allowing the article to dissolve simplifying disposal of the packaging and improving interaction with the article.

Process for Making an Article

Generally, the process of making an article, such as a unit dose article, can include the steps of forming an open pouch, filling the open pouch with a composition, and closing the open pouch filled with the composition. The open pouch can be formed by placing a film into a mold. The pouch can be closed with a second film. As can be appreciated, one or more of the films used to form the article can be the films as described herein. Other articles can be made as known in the art.

As can be further appreciated, vapor-deposited organic and vapor-deposited inorganic coatings as described herein can alternatively be formed on completed articles. In such embodiments, a completed article, such as a unit dose article, can undergo processes similar to the processes used to form vapor-deposited coatings on the film described herein. For example, a plasma-assisted chemical vapor deposition process can be used to form a vapor-deposited organic coating on the outside surface of a unit dose article formed from uncoated PVOH polymer films.

In any embodiment described herein, articles can be formed in a web process which forms multiple articles at once. After the web is sealed, the web can be cut to form individual articles.

Articles described herein can be made by thermoforming, vacuum-forming or a combination thereof. Articles can be sealed using any sealing method known in the art. Suitable sealing methods can include heat sealing, solvent sealing, pressure sealing, ultrasonic sealing, pressure sealing, laser sealing, impulse sealing, infrared (“IR”) sealing, or a combination thereof. For example, water or another suitable aqueous solvent can be applied to an edge to partially dissolve the film allowing a seal to be formed.

In certain examples, an article can also be dusted with a dusting agent, such as talc, silica, zeolite, carbonate, or a mixture thereof to prevent film blocking. As can be appreciated however, the necessity of such dusting agents can be eliminated by the non-tacky nature of the vapor-deposited organic coating.

In certain examples, a package may be formed from these films by a simple form, fill, seal process as used to form packaging sachets and pouches today. Examples of such a process are given in Packaging Digest, such as those described at http://www.packagingdigest.com/form-fill-seal or https://vikingmasek.com/packaging-machine-resources/packaging-machine-blog/a-guide-to-vertical-form-fill-seal-machines.

FIGS. 5A-5D illustrate various embodiments of exemplary soluble unit dose articles; in these figures, flexible materials are illustrated with exaggerated thicknesses in order to more clearly show their positions and relationships.

FIGS. 5A-5D illustrate various views of an exemplary soluble unit dose article 300 having a flat top 301, a rounded bottom 302, and one compartment 331. FIG. 5A is a top view, FIG. 5B is a side view, FIG. 5C is an end view, and FIG. 5D is a cross-sectional end view. In the top view, the overall shape of the article 300 is rectangular with rounded corners. The article 300 is formed by a first flexible material 311 that is sealed to a second flexible material 312 over a sealed area 321. The sealed area 321 forms a continuous connection between the flexible materials 311 and 312, all around the outer periphery of the article 300. Apart from the sealed area 321, the flexible materials 311 and 312 are independent from each other. The first flexible material 311 is disposed above the second flexible material 312, and is oriented about horizontally. On the bottom 302, in the middle of the article 300, the second flexible material 312 curves downward from the sealed area 321 and is offset from the first flexible material 311, such that the space between the flexible materials 311 and 312 forms the compartment 331, which has a side profile with an overall shape like an inverted bell. The compartment 331 surrounds and encloses a composition 341.

FIGS. 6A-6D illustrate various views of an exemplary soluble unit dose article 400 having a rounded top 401, a rounded bottom 402, and one compartment 431. FIG. 6A is a top view, FIG. 6B is a side view, FIG. 6C is an end view, and FIG. 6D is a cross-sectional end view. In the top view, the overall shape of the article 400 is rectangular with rounded corners. The article 400 is formed by a first flexible material 412 that is sealed to a second flexible material 413 over a sealed area 421. The sealed area 421 forms a continuous connection between the flexible materials 412 and 413, all around the outer periphery of the article 400. Apart from the sealed area 421, the flexible materials 411 and 412 are independent from each other. On the bottom 402, in the middle of the article 400, the first flexible material 412 curves downward from the sealed area 421, and on the top 401, in the middle of the article 400, the second flexible material 413 curves upward from the sealed area 421 such that the second flexible material 413 is offset from the first flexible material 412, and the space between the flexible materials 412 and 413 forms the compartment 431, which has a side profile with an overall shape like a pillow. The compartment 431 surrounds and encloses a composition 441.

FIGS. 7A-7D illustrate various views of an exemplary soluble unit dose article 500 having a rounded top 501, a rounded bottom 502, and two overlapping compartments 531 and 532. FIG. 7A is a top view, FIG. 7B is a side view, FIG. 7C is an end view, and FIG. 7D is a cross-sectional end view. In the top view, the overall shape of the article 500 is rectangular with rounded corners. The article 500 is formed by a first flexible material 511, a second flexible material 512, and a third flexible material 513, which are all sealed together over a sealed area 521. The sealed area 521 forms a continuous connection between the flexible materials 511, 512, and 513, all around the outer periphery of the article 500. Apart from the sealed area 521, the flexible materials 511, 512, and 513 are independent from each other. The first flexible material 511 is disposed between the second flexible material 512 and the third flexible material 513, and is oriented about horizontally. On the bottom 502, in the middle of the article 500, the second flexible material 512 curves downward from the sealed area 521 such that the second flexible material 512 is offset from the first flexible material 511, and the space between the flexible materials 511 and 512 forms the first compartment 531, which has a side profile with an overall shape like an inverted bell. The first compartment 531 surrounds and encloses a first composition 541. On the top 501, in the middle of the article 500, the third flexible material 513 curves upward from the sealed area 521 such that the third flexible material 513 is offset from the first flexible material 511, and the space between the flexible materials 512 and 513 forms the second compartment 532, which has a side profile with an overall shape like a bell. The second compartment 532 surrounds and encloses a second composition 542. The article 500 has a side profile with an overall shape like a pillow.

FIGS. 8A-8D illustrate various views of an exemplary soluble unit dose article 600 having a rounded top 601, a flat bottom 602, and two side-by-side compartments 633 and 634. FIG. 8A is a top view, FIG. 8B is a side view, FIG. 8C is an end view, and FIG. 8D is a cross-sectional end view. In the top view, the overall shape of the article 600 is rectangular with rounded corners. The article 600 is formed by a first flexible material 611 that is sealed to a second flexible material 613 over a sealed area 621. The sealed area 621 forms a continuous connection between the flexible materials 611 and 613, all around the outer periphery of the article 600 and through a portion of the middle of the article 600. Apart from the sealed area 621, the flexible materials 611 and 613 are independent from each other. The first flexible material 611 is disposed below the second flexible material 613, and is oriented about horizontally. On the top 601, in a first part of the middle of the article 600, a first portion of the second flexible material 613 curves upward from the sealed area 621 such that that first portion of the second flexible material 613 is offset from the first flexible material 611, and the space between the flexible materials 611 and 613 forms the first compartment 633, which has a side profile with an overall shape like a rounded tube. The first compartment 633 surrounds and encloses a first composition 643. On the top 601, in a second part of the middle of the article 600, a second portion of the second flexible material 613 curves upward from the sealed area 621 such that that second portion of the second flexible material 613 is offset from the first flexible material 611, and the space between the flexible materials 611 and 613 forms the second compartment 634, which has a side profile with an overall shape like a rounded tube. The second compartment 634 surrounds and encloses a second composition 644, which differs from the first composition 643.

FIGS. 9A-9D illustrate various views of an exemplary soluble unit dose article 700 having a rounded top 701, a rounded bottom 702, and two smaller side-by-side compartments 733 and 734 each overlapping a larger bottom compartment 731. FIG. 9A is a top view, FIG. 9B is a side view, FIG. 9C is an end view, and FIG. 9D is a cross-sectional end view. In the top view, the overall shape of the article 700 is rectangular with rounded corners. The article 700 is formed by a first flexible material 711, a second flexible material 712, and a third flexible material 713, which are sealed together over a first sealed area 721 and a second sealed area 722, as described below. The first sealed area 721 forms a continuous connection between the flexible materials 711, 712, and 713, all around the outer periphery of the article 700. The second sealed area 722 forms a continuous connection between the first flexible material 711 and the third flexible material 713, through a portion of the middle of the article 700, between the compartments 733 and 734 (as shown, bounded by the reference lines). Apart from the sealed areas 721 and 722, the flexible materials 711, 712, and 713 are independent from each other. The first flexible material 711 is disposed between the second flexible material 712 and the third flexible material 713, and is oriented about horizontally. On the bottom 702, in the middle of the article 700, the second flexible material 712 curves downward from the sealed area 721 such that the second flexible material 712 is offset from the first flexible material 711, and the space between the flexible materials 711 and 712 forms the larger compartment 731, which has a side profile with an overall shape like an inverted bell. The compartment 731 surrounds and encloses a first composition 741. On the top 701, in a first part of the middle of the article 700, a first portion of the third flexible material 713 curves upward from the sealed areas 721 and 722 such that that first portion of the second flexible material 713 is offset from the first flexible material 711, and the space between the flexible materials 711 and 713 forms the first smaller compartment 733, which has a side profile with an overall shape like a rounded tube. The compartment 733 surrounds and encloses a second composition 743, which differs from the first composition 741. On the top 701, in a second part of the middle of the article 700, a second portion of the second flexible material 713 curves upward from the sealed areas 721 and 722 such that that second portion of the second flexible material 713 is offset from the first flexible material 711, and the space between the flexible materials 711 and 713 forms the second smaller compartment 734, which has a side profile with an overall shape like a rounded tube. The compartment 734 surrounds and encloses a third composition 744, which differs from both the first composition 741 and the second composition 743.

Part, parts, or all of any of the soluble unit dose article embodiments of FIGS. 5A-9D can be made, used, and/or modified in any way known in the art. For example, any of these articles can be configured with any convenient size and shape along with any number of compartments, as described herein and/or as known in the art; as examples, a soluble unit dose article can be configured according to any embodiment disclosed in U.S. Pat. No. 9,725,685 entitled “Unit Dose Article,” which is hereby incorporated by reference, or any commercially available embodiment of a soluble unit dose article (e.g. TIDE PODS and CASCADE ACTION PACS made by The Procter & Gamble Company, of Cincinnati, Ohio, United States of America). Any of the compartments for these articles can be configured with any convenient size, shape, configuration, and relationship, as described herein and/or as known in the art. Any of the compartments for these articles can be filled with one or more of any composition(s) described herein and/or known in the art of soluble unit dose articles; as examples, such compositions can include on or more of any of the following: fabric care compositions (detergents, surfactants, bleaches, fabric softeners, dyes, brighteners, perfumes, etc.), dish care compositions, agrochemicals, water treatment chemicals, dyes, etc. Any of the compositions disclosed herein can take any convenient form disclosed herein or known in the art, such as: liquid, paste, solid, fibrous, granular, powdered, etc. Any of the flexible materials used to form these articles can be the same material, or different versions of the same material, or different materials, as described herein and/or as known in the art; for example, any of the water soluble films disclosed herein can be used (by itself and/or as part of a laminate/composite material) for part, parts, or all of any of these flexible materials. And, any of the water soluble films disclosed herein can be used (by itself and/or as part of a laminate/composite material) to form part, parts, or all of a soluble unit dose article known in the art, and can include any additives and/or coatings (e.g. bitterants, gas-barrier additives, etc), known in the art of soluble unit dose articles. Part, parts, or all of any of these aspects can be combined together in any workable manner to form further alternative embodiments. Further, any of the water soluble films disclosed herein can be used (by itself and/or as part of a laminate/composite material) to form part, parts, or all of components in health and hygiene products, such as disposable diapers and training pants, incontinence articles, and feminine care products (e.g., pads and liners), in medical products such as bags for bodily fluids and/or waste (e.g., ostomy pouches), and in other household products such as trash bags, laundry bags, hamper liners, etc. Water-soluble films also can be used to form embroidery products, beauty products (e.g., face masks that include water soluble components), personal care products, shaving products, health care products, pharmaceuticals, etc. Still further, any of the water soluble films disclosed herein can be used (by itself and/or as part of a laminate/composite material) to form part, parts, or all of a flexible package (e.g. sachet), in order to provide for improved disposability for the package; such packages can have any convenient size and may include any number of doses (e.g. single dose, multiple dose, etc.). Any of the films described herein can be used as part, parts, or all of a primary package, and/or a secondary package, and/or any other kind of package or packaging material known in the art.

Test Methods

Method for Measuring Coating Thicknesses During Coating Process

In order to measure the thickness of the organic coatings put down under certain conditions, a strip of Kapton tape is placed over a cleaned silicon wafer. The wafer is then coated with organic material at the same time that the soluble film sample is coated. The tape is then removed from the silicon wafer, and the thickness of the coated wafer is measured using a KLA Tencor P-15 Profilometer. In order to monitor the thickness of inorganic coatings, an INFICON XTC/3 Thin Film Deposition Controller is used in situ (within the vacuum chamber) during deposition.

Method for Measuring Coating Thickness and Chemical Analysis of Coated Film

In order to measure the thickness of a coating on a film (or even to determine if there is a coating present on a film), high resolution Scanning Electron Microscopy (SEM) can be used. In order to prepare a sample for thickness measurements using high resolution SEM, the sample is cut in half in order to obtain a cross-section using a microtome, preferably a cryogenic microtome in order to get the best cut without smearing the surface to be examined. This assumes that the film is already separated from other elements of a product. However, if the film is part of a commercial consumer product e.g., such as a fabric care unit dose pod product, then a small part of the film is first cut from the product and cleaned. Cleaning can be achieved by carefully wiping any liquid product off the inside of the film that had been directly in contact with the product. Dust and dirt from particles can be removed from the other surface using an air gun. The sample is then placed on a vertical stub using double sided carbon tape to hold the sample in place. The sample can be sputter coated with Au—Pd prior to SEM analysis, to ensure a good image. The cross-sectional area of the sample is examined to determine if a coating is present on either of the film surfaces. If present, the thickness of the coating is determined by the scale on the SEM.

To determine the chemical composition of the coating, EDAX (typically attached to an SEM) can be used in order to determine the chemical composition of both organic or inorganic coatings. In addition, FTIR can also be used to identify the chemical identity of organic coatings and XPS can also be used to identify the chemical identity of both organic and inorganic coatings.

A sample for chemical identification is prepared by cutting a small fragment from the finished product and clean it as described previously. No other preparation is needed for FTIR analysis. If EDAX is being used, the sample is placed on a stub with double sided carbon tape (the samples would not be coated with Au—Pd for EDAX analysis). For XPS analysis, the sample is placed on a silicon wafer, anchoring the sample with carbon tape (or any other vacuum compatible tape) at the corners.

Method for Observing Microfractures

A scanning electron microscope (SEM) is used to observe the surface of the uncoated film, including the microfractures in the inorganic coating, and to observe the surface of the organic coating. The SEM images of 1000 nm Al₂O₃ before and after stretching are taken with a Hitachi TM3000 Bench-top SEM. In some cases (for Al₂O₃ coatings that need higher magnification) a FEI XL-30 ESEM is used. In order to prepare a sample for SEM imaging, a sample is placed on a metal stub using double sided carbon tape to hold the sample in place. Organic coatings might have low visibility when being evaluated with SEM and if this is the case, the samples are sputter coated using an Au—Pd target to deposit 80-100 nm thickness of Au—Pd prior to SEM. Where samples were stretched, they were stretched using an Instron machine. In order to stretch films, an Instron 5948 MicroTester is used. If a sample is stretched from 1 cm to 2.5 cm, we say that it is stretched to 150% of its original length.

Oxygen Transmission Rate Test Method

The Oxygen Transmission Rate Test Method for a film is performed according to the following. The specimens are tested according to ASTM F-1927-14, under the following test conditions: temperature of 40° C. (+/−0.5° C.), relative humidity of 80% (+/−3%), wherein the oxygen partial pressure on the test gas side is equal to the oxygen partial pressure on the carrier gas side (both being the ambient pressure). The oxygen transmission rate is measured in (or converted to) units of cm³/(m²·day). For materials outside of the Scope (§ 1.1) of ASTM F-1927-14, the Oxygen Transmission Rate Test Method does not apply.

Water Vapor Transmission Rate Test Method

The Water Vapor Transmission Rate Test Method for is performed according to the following. The specimens are tested according to ASTM F-1249-13, under the following test conditions: temperature of 40° C. (+/−0.56° C.) and relative humidity of 50% (+/−3%). The water vapor transmission rate is measured in (or converted to) units of g/(m²·day). For materials outside of the Scope (§ 1.1) of ASTM F-1249-13, the Water Vapor Transmission Rate Test Method does not apply.

Dissolution Test Method

The Dissolution Test Method for a water-soluble film measures the total time (in seconds) for complete dissolution of a particular film specimen when the test is performed according to Slide Dissolution Test, which is MONOSOL Test Method 205 (MSTM 205), as set forth in paragraphs 116-131 of US published patent application US20150093526A1, entitled “Water-soluble film having improved dissolution and stress properties, and packets made therefrom,” the entire publication is hereby incorporated by reference; the Dissolution Test Method used herein is the same as that set forth in US20150093526A1, except that in the Dissolution Test Method of the present disclosure, instead of maintaining the distilled water at 10° C., the distilled water is maintained at 15° C. While the standard version of the Dissolution Test Method uses distilled water maintained at 15° C., the Dissolution Test Method may be run in modified form with the distilled water maintained at another specified temperature, in order to provide further comparative data at a different temperature. The Dissolution Test Method does not apply to any materials other than water-soluble films having an overall thickness less than or equal to 3 millimeters.

Tack Testing Method—Tack Properties

The films described herein can also exhibit reduced tack compared to uncoated water-soluble films. For example, the films described herein can exhibit a tack force of about 5,000 N or less when measured in accordance to the Tack Force method. An uncoated polyvinyl alcohol film can have a tack force of more than 30,000 N.

In the Tack Force method, two samples of a film are cut and mounted to a texture analyzer (Texture Analyzer XT Plus by Texture Technologies (Hamilton, Mass.)) using 5 cm×5 cm pieces of double-sided tape. The top sample is 5 cm×6 cm in size. The bottom sample is 7 cm×10 cm in size. The samples are evaluated at a temperature of 22° C. and 35% relative humidity using a 50 kg load cell with a contact time of 2 seconds. Prior to measurement of the tack force, the sample are sprayed with water at 0.2 bar of pressure from a distance of 110 mm and allowed to relax for 10 seconds.

Other Testing Requirements

When testing and/or measuring a material, if the relevant test method does not specify a particular temperature, then the testing and/or measuring is performed on specimens at a temperature of 22° C. (+/−3° C.) (with such specimens preconditioned to that temperature). When testing and/or measuring a material, if the relevant test method does not specify a particular humidity, then the testing and/or measuring is performed on specimens at a relative humidity of 35% (+/−5%) (with such specimens preconditioned to that humidity). All tools and/or instruments for testing and/or measuring must be properly calibrated before the testing and/or measuring. All testing and/or measuring should be conducted by trained, skilled, and experienced technologists. All testing and/or measuring should be conducted according to good laboratory practices, with the goal of obtaining accurate results.

Table 3 evaluates the water vapor transmission rates and oxygen transmission rates of various films. The 76 micron films of Table 3 were evaluated in accordance to the previously described ASTM standards as outlined in the Test Method section.

Oxygen transmission rates for Table 3 were measured in accordance to ASTM D-3985 and F-1927 as outlined in the test method section.

TABLE 1 Water Vapor Oxygen Transmission Rate Transmission Rate (g/(m² · day)) (cc/(m² · day) Examples [g/(100 in² · day)] [cc/(100 in² · day)] Comparative Example 1 -  233 [15.0] 324 [20.9] Uncoated PVOH 1 (Avg. of 2 samples) (Avg. of 2 samples) Inventive Example 2 - Ex. 1 + 82.6 [5.33] 240 [15.5] 300 nm poly(chloro-p- (Avg. of 2 samples) xylylene) polymer coating Inventive Example 3 - Ex. 1 + 23.9 [1.54] 165.1 [10.65]  1,000 nm Al₂O₃ coating + 300 nm poly(chloro-p- xylylene) polymer coating Inventive Example 4 - Ex. 1 + 92.8 [5.99] — 300 nm Al₂O₃ coating + 300 nm poly(chloro-p- xylylene) polymer coating Inventive Example 5 - Ex. 1 + 36.1 [2.33] — 100 nm Al₂O₃ coating + (Avg. of 2 samples) 300 nm poly(chloro-p- xylylene) polymer coating Inventive Example 6 - Ex. 1 + 82.5 [5.32] 141 [9.1]  SiO_(x) + 300 nm poly(chloro-p- xylylene) polymer coating

As illustrated in Table 1, each film including a vapor-deposited organic coating demonstrated reduced water vapor and oxygen transmission rates compared to the uncoated films described in the Comparative Examples.

Unit dose articles were also manufactured and evaluated using the films described herein.

Table 2 depicts the film constructions and separation force of several example unit dose articles. Separation force was determined by clamping the example unit dose article in a bottom test clamp and a unit dose article with no vapor-deposited coating in an upper test clamp. A water nozzle was then used to spray the example unit dose article with water for 2 seconds. The upper unit dose article was then lowered to contact the example unit dose article. The unit dose articles were held together for 10 minutes with 150 grams of force. After 10 minutes, the unit dose articles were separated at 33.33 mm/s and the force required to separate the soluble unit dose articles was measured. Comparative Example 7 was measured in two different sets of test runs.

TABLE 2 Example No. Film Construction Separation Force (g) Comparative Uncoated PVOH 779 ± 88; 414 ± 186 Example 7 Inventive Ex. 7 + ablation + 150 nm 177 ± 46 Example 8 poly(chloro-p-xylylene) Inventive Ex. 7 + ablation + 75 nm 211 ± 43 Example 9 poly(chloro-p-xylylene) Inventive Ex. 7 + 150 nm 146 ± 5  Example 10 poly(chloro-p-xylylene) Inventive Ex. 7 + 100 nm 41 ± 7 Example 11 Al₂O₃ + 150 nm poly(chloro-p-xylylene) Inventive Ex. 7 + 1,000 nm  86 ± 60 Example 12 Al₂O₃ + 150 nm poly(chloro-p-xylylene)

As depicted in Table 2, unit dose articles formed with films having a vapor-deposited organic coating show dramatic reductions in separation force when compared to unit dose articles formed from films without a vapor-deposited organic coating. Additionally, unit dose articles formed from films having a vapor-deposited coating have less variability in separation force.

Table 3 depicts the time required for an example unit dose article to rupture when submerged in distilled water having a temperature of 21.1° C. Each example unit dose article was formed from two PVOH films as described in Table 3. The example unit dose articles were submerged to a depth of 1 cm in water and observed until a sealed juice was observed to leak out. A mirror was placed underneath the examples to assist in observing the burst time. This test is referred to as the Soluble Unit Dose Burst test.

TABLE 3 Rupture Time Example No. Film Construction (seconds) Comparative Uncoated PVOH   8 Example 13 Inventive Ex. 13 + 1,000 nm 1,237* Example 14 Al₂O₃ + 150 nm poly(chloro-p-xylylene) Inventive Ex. 13 + 1,000 nm  209 Example 15 Al₂O₃ + 150 nm poly(chloro-p-xylylene) *Example may have ruptured prior to recorded observation time

As depicted in Table 3, example unit dose articles formed from films including a vapor-deposited inorganic coating and a vapor-deposited organic coating exhibited dramatically longer rupture times than a comparative unit dose article formed from films without a vapor-deposited coating.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments and examples of the present disclosure have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

EXAMPLES/COMBINATIONS

A1. A film comprising:

a layer of water-soluble polymeric material; and

a vapor-deposited organic coating disposed on a surface of the layer of water-soluble polymeric material, wherein the vapor-deposited coating comprises a poly(p-xylylene) polymer.

A2. The film of paragraph A1, wherein the vapor-deposited coating substantially consists of the poly(p-xylylene) polymer.

A3. The film of paragraph A1, wherein the vapor-deposited coating consists of the poly(p-xylylene) polymer.

A4. The film of any of paragraphs A1 to A3, wherein the poly(p-xylylene) polymer comprises one or more of poly(chloro-p-xylylene) polymer, poly(p-xylylene) polymer, poly(dichloro-p-xylylene) polymer, a-perfluorodi-p-xylene polymer, and poly(tetrafluoro-p-xylylene) polymer. A5. The film of any of paragraphs A1 to A4, wherein the poly(p-xylylene) polymer comprises poly(chloro-p-xylylene). A6. The film of any of paragraphs A1 to A5, wherein the vapor-deposited coating is directly applied to the at least one surface of the layer of water-soluble polymeric material. A7. The film of any of paragraphs A1 to A6, wherein the at least one surface of the layer of water-soluble polymeric material is at least partially ablated. A8. The film of any of paragraphs A1 to A7, wherein the at least one surface of the layer of water-soluble polymeric material is substantially fully ablated. A9. The film of paragraph A7 or paragraph A8, wherein the layer of water-soluble polymeric material is ablated with one or more of a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment. A10. The film of any of paragraphs A7 to A9, wherein the layer of water-soluble polymeric material is ablated with a helium-oxygen plasma or an argon-oxygen plasma. A11. The film of any of paragraphs A1 to A10, wherein the layer of water-soluble polymeric material is solution cast. A12. The film of any of paragraphs A1 to A11, wherein the layer of water-soluble polymeric material is extruded. A13. The film of any of paragraphs A1 to A12, wherein the layer of water-soluble polymeric material comprises one or more of polyvinyl alcohol, a copolymer of vinyl alcohol and butene-diol, polyethylene glycol, and polyethylene oxide. A14. The film of any of paragraphs A1 to A13, wherein the layer of water-soluble polymeric material consists essentially of polyvinyl alcohol. A15. The film of any of paragraphs A1 to A14, wherein the layer of water-soluble polymeric material further comprises one or more plasticizers, gas-barrier additives, and bittering agents. A16. The film of any of paragraphs A1 to A15 comprising a plurality of layers of water-soluble polymeric material. A17. The film of any of paragraphs A1 to A16 has a thickness of about 5 microns to about 300 microns. A18. The film of any of paragraphs A1 to A17 has a thickness of about 50 microns to about 100 microns. A19. The film of any of paragraphs A1 to A18, wherein the organic vapor-deposited coating has a thickness of about 10 nanometers to about 1,000 nanometers. A20. The film of any of paragraphs A1 to A19, wherein the vapor-deposited organic coating has a thickness of about 100 nanometers to about 500 nanometers. A21. The film of any of paragraphs A1 to A20, wherein the vapor-deposited coating is joined to about 60%, or more, of the at least one surface of the layer of water-soluble polymeric material. A22. The film of any of paragraphs A1 to A21, wherein the vapor-deposited coating is joined to about 95%, or more, of the at least one surface of the layer of water-soluble polymeric material. A23. The film of any of paragraphs A1 to A22:

wherein the vapor-deposited coating has a thickness of about 125 nanometers to about 500 nanometers and consists essentially of poly(chloro-p-xylylene); and

wherein the film has a thickness of about 76 microns and exhibits a water vapor transmission rate of about 46.5 g/(m²·day) [3 g/(100 in²·day)] to about 124 g/(m²·day) [8 g/(100 in²·day)] when measured in accordance to ASTM F-1249.

A24. The film of any of paragraphs A1 to A23:

wherein the vapor-deposited coating has a thickness of about 25 nanometers to about 500 nanometers and consists essentially of poly(chloro-p-xylylene); and

wherein the film has a thickness of about 76 microns and exhibits an oxygen transmission rate of about 124 cc/(m²·day) [8 cc/(100 in²·day)] to about 232.5 cc/(m²·day) [15 cc/(100 in²·day)] when measured in accordance to ASTM D-3985 and F-1927.

A25. The film of any of paragraphs A1 to A24, wherein the vapor-deposited coating is joined to only one surface of the layer of water-soluble polymeric material.

A26. The film of any of paragraphs A1 to A25, further comprising a vapor-deposited inorganic coating joined to the vapor-deposited coating.

A27. An article comprising a film of any of paragraphs A1 to A26 wherein the film forms at least part of packaging for the article.

A28. The article of paragraph A27, wherein the article is a soluble unit dose article.

B. A film comprising:

a layer of water-soluble polyvinyl alcohol; and

a vapor-deposited coating joined to a primary surface of the layer of polyvinyl alcohol, the vapor-deposited coating comprising poly(chloro-p-xylylene) and having a thickness of about 25 nanometers to about 500 nanometers; and

wherein the film has a thickness of about 76 microns and exhibits a water vapor transmission rate of about 62 g/(m²·day) [4 g/(100 in²·day)] to about 93 g/(m²·day) [6 g/(100 in²·day)] when measured in accordance to ASTM F-1249.

C. A film comprising:

a layer of water-soluble polyvinyl alcohol; and

a vapor-deposited coating joined to a primary surface of the layer of polyvinyl alcohol, the vapor-deposited coating comprising poly(chloro-p-xylylene) and having a thickness of about 125 nanometers to about 500 nanometers; and

wherein the film has a thickness of about 76 microns and exhibits an oxygen transmission rate of about 186 cc/(m²·day) [12 cc/(100 in²·day)] to about 279 cc/(m²·day) [18 cc/(100 in²·day)] when measured in accordance to ASTM D-3985 and F-1927.

D1. A method of forming a film comprising:

providing a layer of water-soluble polymeric material; and

vapor depositing an organic coating to at least one surface of the layer of water-soluble polymeric material, wherein the organic coating comprises a poly(p-xylylene) polymer.

D2. The method of paragraph D1, wherein vapor depositing uses chemical vapor deposition.

D3. The method of paragraph D2, wherein vapor depositing uses plasma-assisted chemical vapor deposition.

D4. The method of any of paragraphs D1 to D3 further comprising at least partially ablating the at least one surface of the layer of water-soluble polymeric material.

D5. The method of any of paragraphs D1 to D4, wherein the at least one surface of the layer of water-soluble polymeric material is substantially fully ablated.

D6. The method of paragraph D4 or paragraph D5, wherein the at least one surface of the layer of water-soluble polymeric material is ablated with one or more of a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment. D7. The method of any of paragraphs D4 to D6, wherein ablating uses helium-oxygen plasma or an argon-oxygen plasma. E1. A film comprising:

a layer of water-soluble polymeric material;

a vapor-deposited inorganic coating joined to at least one surface of the layer of water-soluble polymeric material, wherein the vapor-deposited inorganic coating comprises a metal oxide; and

a vapor-deposited organic coating joined to the vapor-deposited inorganic coating, wherein the vapor-deposited organic coating comprises a poly(p-xylylene) polymer.

E2. The film of paragraph E1, wherein the vapor-deposited organic coating substantially consists of the poly(p-xylylene) polymer.

E3. The film of paragraph E1, wherein the vapor-deposited organic coating consists of the poly(p-xylylene) polymer.

E4. The film of any of paragraphs E1 to E3, wherein the metal oxide comprises one or more of aluminum oxide, silicon oxide, magnesium oxide, and titanium oxide.

E5. The film of any of paragraphs E1 to E4, wherein the vapor-deposited inorganic coating has a thickness of about 2 nanometers to about 1,000 nanometers.

E6. The film of any of paragraphs E1 to E5, wherein the vapor-deposited organic coating has a thickness of about 10 nanometers to about 1,000 nanometers.

E7. The film of any of paragraphs E1 to E6, wherein the vapor-deposited inorganic coating comprises a plurality of microfractures.

E8. The film of any of paragraphs E1 to E7, wherein the vapor-deposited organic coating is substantially free from microfractures and covers a portion of the plurality of microfractures present in the vapor-deposited inorganic coating.

E9. The film of any of paragraphs E1 to E8, wherein the vapor-deposited organic coating is substantially free from microfractures and covers substantially all of the plurality of microfractures present in the vapor-deposited inorganic coating.

E10. The film of any of paragraphs E1 to E9, wherein the vapor-deposited organic coating is substantially free from microfractures and covers all of the plurality of microfractures present in the vapor-deposited inorganic coating.

E11. The film of any of paragraphs E1 to E10 comprising a plurality of layers of water-soluble polymeric material.

E12. The film of any of paragraphs E1 to E11, wherein the vapor-deposited inorganic coating is joined to about 60%, or more, of the surface of the layer of water-soluble polymeric material.

E13. The film of any of paragraphs E1 to E12, wherein the vapor-deposited inorganic coating is joined to about 95%, or more, of the surface of the layer of water-soluble polymeric material.

E14. The film of any of paragraphs E1 to E13, wherein the vapor-deposited organic coating is joined to about 60%, or more, of vapor-deposited inorganic coating.

E15. The film of any of paragraphs E1 to E14, wherein the vapor-deposited organic coating is joined to about 95%, or more, of vapor-deposited inorganic coating.

E16. The film of any of paragraphs E1 to E15, wherein the vapor-deposited inorganic coating is directly applied to the at least one surface of the layer of water-soluble polymeric material.

E17. The film of any of paragraphs E1 to E16, wherein the at least one surface of the layer of water-soluble polymeric material is at least partially ablated.

E18. The film of any of paragraphs E1 to E17, wherein the at least one surface of the layer of water-soluble polymeric material is substantially fully ablated.

E19. The film of paragraph E17 or paragraph E18, wherein the layer of water-soluble polymeric material is ablated with one or more of a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment. E20. The film of any of paragraphs E17 to E19, wherein the layer of water-soluble polymeric material is ablated with a helium-oxygen plasma or an argon-oxygen plasma. E21. The film of any of paragraphs E1 to E20:

wherein the vapor-deposited organic coating has a thickness of about 25 nanometers to about 500 nanometers and comprises poly(chloro-p-xylylene);

wherein the vapor-deposited inorganic coating has a thickness of about 2 nanometers to about 1000 nanometers; and

wherein the film has a thickness of about 76 microns and exhibits a water vapor transmission rate of about 7.75 g/(m²·day) [0.5 g/(100 in²·day)] to about 124 g/(m²·day) [8 g/(100 in²·day)] when measured in accordance to ASTM F-1249.

E22. The film of any of paragraphs E1 to E21:

wherein the vapor-deposited organic coating has a thickness of about 25 nanometers to about 500 nanometers and comprises poly(chloro-p-xylylene);

wherein the vapor-deposited inorganic coating has a thickness of about 2 nanometers to about 1000 nanometers; and

wherein the film has a thickness of about 76 microns and exhibits a water vapor transmission rate of about 15.5 g/(m²·day) [1 g/(100 in²·day)] to about 46.5 g/(m²·day) [3 g/(100 in²·day)] when measured in accordance to ASTM F-1249.

E23. The film of any of paragraphs E1 to E22:

wherein the vapor-deposited organic coating has a thickness of about 25 nanometers to about 500 nanometers and consists essentially of poly(chloro-p-xylylene);

wherein the vapor-deposited inorganic coating has a thickness of about 2 nanometers to about 1000 nanometers; and

wherein the film has a thickness of about 76 microns and exhibits an oxygen transmission rate of about 77.5 cc/(m²·day) [5 cc/(100 in²·day)] to about 279 cc/(m²·day) [18 cc/(100 in²·day)] when measured in accordance to ASTM D-3985 and F-1927.

E24. The film of any of paragraphs E1 to E24, wherein the layer of polymeric material comprises one or more of polyvinyl alcohol, a copolymer of vinyl alcohol and butene-diol, polyethylene glycol, and polyethylene oxide.

E25. The film of any of paragraphs E1 to E25, wherein the layer of polymeric material consists essentially of polyvinyl alcohol.

E26. The film of any of paragraphs E1 to E26 has a thickness of about 5 microns to about 300 microns.

E27. The film of any of paragraphs E1 to E27, wherein the surface of the at least one layer of water-soluble polymeric material is unablated.

E28. The film of any of paragraphs E1 to E28, wherein the vapor-deposited organic coating is directly applied to the vapor-deposited inorganic coating.

E29. The film of any of paragraphs E1 to E29, wherein the vapor-deposited inorganic coating is joined to only one surface of the layer of water-soluble polymeric material.

E30. An article comprising a film of any of paragraphs E1 to E29 wherein the film forms at least part of packaging for the article.

E31. The article of paragraph E30, wherein the article is a soluble unit dose article.

F. A film comprising:

a layer of water-soluble polyvinyl alcohol;

a vapor-deposited inorganic coating joined to at least one surface of the layer of water-soluble polyvinyl alcohol, wherein the vapor-deposited inorganic coating comprises a metal oxide and has a thickness of about 2 nanometers to about 1000 nanometers; and

a vapor-deposited organic coating joined to a surface of the vapor-deposited inorganic coating, wherein the vapor-deposited organic coating comprises poly(chloro-p-xylylene) and has a thickness of about 25 nanometers to about 500 nanometers; and

wherein the film has a thickness of about 76 microns and exhibits a water vapor transmission rate of about 15.5 g/(m²·day) [1 g/(100 in²·day)] to about 46.5 g/(m²·day) [3 g/(100 in²·day)] when measured in accordance to ASTM F-1249.

G. A film comprising:

a layer of water-soluble polyvinyl alcohol;

a vapor-deposited inorganic coating joined to at least one surface of the layer of water-soluble polyvinyl alcohol, wherein the vapor-deposited inorganic coating comprises a metal oxide and has a thickness of about 2 nanometers to about 1000 nanometers; and

a vapor-deposited organic coating joined to a surface of the vapor-deposited inorganic coating, wherein the vapor-deposited organic coating comprises poly(chloro-p-xylylene) and has a thickness of about 25 nanometers to about 500 nanometers; and

wherein the film has a thickness of about 76 microns and exhibits an oxygen transmission rate of about 77.5 cc/(m²·day) [5 cc/(100 in²·day)] to about 232.5 cc/(m²·day) [15 cc/(100 in²·day)] when measured in accordance to ASTM D-3985 and F-1927.

H1. A method of forming a film comprising:

providing a layer of water-soluble polymeric material;

vapor depositing an inorganic coating to at least one surface of the layer of water-soluble polymeric material, wherein the inorganic coating comprises a metal oxide; and

vapor depositing an organic coating to the surface of the inorganic coating, wherein the coating comprises a poly(p-xylylene) polymer.

H2. The method of paragraph H1, wherein the at least one surface of the layer of water-soluble polymeric material is unablated.

H3. The method of paragraph H1 or paragraph H2, wherein one or more of the inorganic coating and the organic coating are vapor-deposited with a chemical vapor deposition process.

H4. The method of paragraph H3, wherein the chemical vapor deposition process is a plasma-assisted chemical vapor deposition process. 

What is claimed is:
 1. A method of forming a soluble unit dose article comprising: forming a film by providing a first layer of water-soluble polymeric material and vapor depositing an organic coating to at least one surface of the first layer of water-soluble polymeric material to form a second layer, wherein the organic coating comprises a poly(p-xylylene) polymer; vapor depositing a third layer comprising an inorganic coating to at least one surface of the first layer of water-soluble polymeric material; wherein the inorganic coating comprises a plurality of microfractures; forming an open pouch from the film; filling the open pouch with a composition; and closing the open pouch.
 2. The method of claim 1, wherein vapor depositing uses chemical vapor deposition.
 3. The method of claim 1, wherein vapor depositing uses plasma-assisted chemical vapor deposition.
 4. The method of claim 1, further comprising partially ablating the at least one surface of the first layer of water-soluble polymeric material.
 5. The method of claim 4, wherein the at least one surface of the first layer of water-soluble polymeric material is partially ablated with one or more of a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment.
 6. The method of claim 4, wherein the at least one surface of the first layer of water-soluble polymeric material is partially ablated with helium-oxygen plasma or an argon-oxygen plasma.
 7. The method of claim 1, further comprising substantially fully ablating the at least one surface of the first layer of water-soluble polymeric material.
 8. The method of claim 7, wherein the at least one surface of the first layer of water-soluble polymeric material is substantially fully ablated with one or more of a plasma treatment, a solvent treatment, a flame treatment, a photon ablation treatment, an electron beam irradiation treatment, an ion bombardment treatment, an ultraviolet treatment, a vacuum annealing treatment, or a physical abrasion treatment.
 9. The method of claim 7, wherein the at least one surface of the first layer of water-soluble polymeric material is substantially fully ablated with helium-oxygen plasma or an argon-oxygen plasma.
 10. The method of claim 1, wherein the water-soluble polymeric material comprises polyvinyl alcohol.
 11. The method of claim 1, wherein the poly(p-xylylene) polymer comprises one or more of poly(p-xylylene) polymer, poly(dichloro-p-xylylene) polymer, α-perfluorodi-p-xylene polymer, and poly(tetrafluoro-p-xylylene) polymer.
 12. The method of claim 1, wherein the organic coating consists of the poly(p-xylylene) polymer.
 13. The method of claim 1, wherein the organic coating is directly attached to the surface of the first layer comprising the water-soluble polymeric material.
 14. The method of claim 1, wherein the organic coating has a thickness of from about 10 to about 500 nanometers.
 15. The method of claim 1, wherein the inorganic coating comprises a metal oxide.
 16. The method of claim 1, wherein the second layer is substantially free from microfractures and covers a portion of the plurality of microfractures in the third layer.
 17. The method of claim 1, wherein the third layer is directly attached to a surface of the first layer.
 18. The method of claim 17, wherein the second layer is directly attached to a surface of the third layer. 